Abstract: A method for nondestructive testing includes steps of: (1) forming a first inspection standard using a metal injection molding process; (2) forming a second inspection standard using the metal injection molding process; and (3) creating a reference library that includes the first inspection standard and the second inspection standard. The first inspection standard includes first voids that are induced by a first set of conditions of a sintering operation and a hot isostatic pressing operation of the metal injection molding process. The second inspection standard includes second voids that are induced by a second set of the conditions of the sintering operation and the hot isostatic pressing operation. At least one of the conditions in the second set of the conditions is different than at least one of the conditions of the first set of the conditions. The first voids and the second voids are different.

Abstract: A nondestructive inspection method includes steps of: (1) forming a first inspection standard using a metal injection molding process; (2) forming a second inspection standard using the metal injection molding process; and (3) creating a reference library that includes the first and the second inspection standards. The first inspection standard includes a first crack, induced by at least one of a thermal shock and a thermal stress. The second inspection standard includes a second crack, induced by at least one of the thermal shock and the thermal stress. At least one of the thermal shock and the thermal stress introduced during a sintering operation for the first inspection standard is different than at least one of the thermal shock and the thermal stress introduced during the sintering operation for the second inspection standard. The first crack and the second crack are different.

Abstract: Standards for non-destructive testing methodologies and methods of fabricating the standards are disclosed herein. The standards include a void-defect coupon that includes a spheroidal void and an elongated void. The spheroidal void has a maximum dimension and a spheroidal void volume. The elongated void had a longitudinal dimension, a maximum transverse dimension, and an elongated void volume. The longitudinal dimension of the elongated void is greater than the maximum dimension of the spheroidal void. The maximum transverse dimension of the elongated void is less than the maximum dimension of the spheroidal void. The methods include forming a first void-defect coupon and forming a second void-defect coupon.

Abstract: A method of removing flash from a gauge portion of a monolithic precursor test coupon using a flash-removal tool is provided. The flash-removal tool comprises a tool body, extending along a longitudinal tool axis, a tooth, and an engagement surface, spaced apart from the tooth along the longitudinal tool axis. The tooth projects from the tool body in a first direction and comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction. The method comprises steps of coupling the engagement surface of the flash-removal tool against a first precursor-coupon end of the monolithic precursor test coupon, orienting the longitudinal tool axis parallel to a longitudinal symmetry axis of the monolithic precursor test coupon, wherein the shearing surface registers longitudinally with the flash, and shearing, using the shearing surface, the flash from the gauge portion.

Abstract: A method of making a test coupon using a mold is provided. The mold defines a mold cavity that comprises a first-grip-portion cavity, a second-grip-portion cavity, an intermediate-portion cavity, interconnecting the first-grip-portion cavity and the second-grip-portion cavity, and runner cavities, directly interconnecting the first-grip-portion cavity and the second-grip-portion cavity and not directly connected to the intermediate-portion cavity. The method comprises injecting feedstock material, comprising a metal powder, into the mold cavity to form a monolithic precursor test coupon in the mold cavity, wherein the monolithic precursor test coupon comprises a first grip portion, a second grip portion, an intermediate portion, and runners. The method also comprises removing the runners from the monolithic precursor test coupon.

Abstract: A flash-removal tool comprises a tool body, extending along a longitudinal tool axis, and a tooth, projecting from the tool body in a first direction. The flash-removal tool further comprises an engagement surface, perpendicular to the longitudinal tool axis and located a preselected distance away from the tooth along the longitudinal tool axis. The tooth comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction. The first direction and the second direction are orthogonal to each other and define a plane, perpendicular to the longitudinal tool axis.

Abstract: A metal-injection-molding (MIM) apparatus for making a monolithic precursor test coupon comprises a mold, defining a mold cavity. The mold cavity comprises a first-grip-portion cavity and a second-grip-portion cavity. The mold cavity also comprises an intermediate-portion cavity, interconnecting the first-grip-portion cavity and the second-grip-portion cavity. The mold cavity further comprises runner cavities, directly interconnecting the first-grip-portion cavity and the second-grip-portion cavity and not directly connected to the intermediate-portion cavity. The MIM apparatus additionally comprises an injector, operable to inject feedstock material that comprises a metal powder, into the mold cavity to form the monolithic precursor test coupon.

Abstract: A flash-removal tool comprises a tool body, extending along a longitudinal tool axis, and a tooth, projecting from the tool body in a first direction. The flash-removal tool further comprises an engagement surface, perpendicular to the longitudinal tool axis and located a preselected distance away from the tooth along the longitudinal tool axis. The tooth comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction. The first direction and the second direction are orthogonal to each other and define a plane, perpendicular to the longitudinal tool axis.

Abstract: A monolithic precursor test coupon includes a first grip portion, a second grip portion, and an intermediate portion, interconnecting the first grip portion and the second grip portion. The monolithic precursor test coupon also includes runners, directly interconnecting the first grip portion and the second grip portion and not directly connected to the intermediate portion. The first grip portion, the second grip portion, the intermediate portion, and the runners are composed of a substance that comprises metal powder and that is in a green state.

Abstract: A titanium alloy composition that includes, other than impurities, about 7.0 to about 9.0 percent by weight vanadium (V), about 3.0 to about 4.5 percent by weight aluminum (Al), about 0.8 to about 1.5 percent by weight iron (Fe), about 0.14 to about 0.22 percent by weight oxygen (O), optionally about 0.8 to about 2.4 percent by weight chromium (Cr), and the balance titanium.

Abstract: Methods and apparatuses are provided for creation of discrete corrosion defects with a wide range of diameter to depth aspect ratios for painted test standards. Also provided are methods for use of those test standards to characterize the corrosion under paint detection threshold, statistical reliability, and accuracy of NDI and/or NDT techniques including but not limited to flash thermography, ultrasonic testing, eddy current testing, microwave testing, shearography, and infrared testing.

Abstract: Methods and apparatuses are provided for creation of discrete corrosion defects with a wide range of diameter to depth aspect ratios for painted test standards. Also provided are methods for use of those test standards to characterize the corrosion under paint detection threshold, statistical reliability, and accuracy of NDI and/or NDT techniques including but not limited to flash thermography, ultrasonic testing, eddy current testing, microwave testing, shearography, and infrared testing.

Abstract: Methods and apparatuses are provided for creation of discrete corrosion defects with a wide range of diameter to depth aspect ratios for painted test standards. Also provided are methods for use of those test standards to characterize the corrosion under paint detection threshold, statistical reliability, and accuracy of NDI and/or NDT techniques including but not limited to flash thermography, ultrasonic testing, eddy current testing, microwave testing, shearography, and infrared testing.

Abstract: Methods and apparatuses are provided for creation of discrete corrosion defects with a wide range of diameter to depth aspect ratios for painted test standards. Also provided are methods for use of those test standards to characterize the corrosion under paint detection threshold, statistical reliability, and accuracy of NDI and/or NDT techniques including but not limited to flash thermography, ultrasonic testing, eddy current testing, microwave testing, shearography, and infrared testing.

Abstract: Methods and apparatuses are provided for creation of discrete corrosion defects with a wide range of diameter to depth aspect ratios for painted test standards. Also provided are methods for use of those test standards to characterize the corrosion under paint detection threshold, statistical reliability, and accuracy of NDI and/or NDT techniques including but not limited to flash thermography, ultrasonic testing, eddy current testing, microwave testing, shearography, and infrared testing.

Abstract: Methods and apparatuses are provided for creation of discrete corrosion defects with a wide range of diameter to depth aspect ratios for painted test standards. Also provided are methods for use of those test standards to characterize the corrosion under paint detection threshold, statistical reliability, and accuracy of NDI and/or NDT techniques including but not limited to flash thermography, ultrasonic testing, eddy current testing, microwave testing, shearography, and infrared testing.

Abstract: A cylinder head gasket for use in a marine engine adapted to be cooled by the water in which the engine is running, the engine having a non-ferrous alloy cylinder head and a non-ferrous alloy engine block, both the block and cylinder head preferably being made of aluminum alloy. The gasket includes a metallic sheet forming a core, the core having upper and lower surfaces, layers of facing material securely disposed upon those upper and lower surfaces, and wherein the electrolytic solution potential of the metallic sheet is approximately equal to the respective electrolytic solution potentials of the engine block and the cylinder head.